Application of optimized digital workflow in full-arch implant prostheses fabrication: multi-source data integration, time efficiency, and precision matching

In contemporary dental laboratories, leveraging advanced digital technologies is transforming the production of full-arch implant prostheses. This study showcased a streamlined workflow using Exocad software, integrating both preoperative and postoperative datasets for precise prostheses fabrication. The key advantages of this workflow include the consolidation of patients’ craniofacial data into a unified coordinate system, enabling seamless integration of diverse DICOM datasets. By calibrating surface thresholds to different critical values, two distinct DICOM surfaces were accurately matched within a minimum tolerance, ensuring the passive fit of the implant. Additionally, preoperative aesthetic and occlusal functional designs significantly reduced processing time during fabrication. The technical implementation involved two stages of data mediation. First, postoperative gingival scan-bar data was mapped onto computed tomography (CT) data of the maxillary skeleton captured with radiographic guides. Next, intraoral scan-bar implant data was aligned with the preoperative radiographic guide CT dataset using gingival scan-bar oral scanning data as an intermediary. This dual mediation approach, combined with precise surface threshold calibration, delivers an exact and efficient workflow that integrates functional and aesthetic design with unparalleled precision in implant prosthetics fabrication. This study explored the potential of this digital protocol in optimizing full-arch implant prosthesis design and fabrication, highlighting its impact on time efficiency, precision, and patient outcomes with Exocad software as a cornerstone of innovation in dental labs.